Methods and systems for multiple-material fence construction

ABSTRACT

Various fencing methods are now common where the structure of the fence does not readily lend itself to the attachment of a mesh fabric, such as, wire weave or chain-link. Methods and systems are provided to evasively and non-evasively attach mesh fabric to a new or existing fence structure (e.g., PVC) as, for example, a connector for an existing fence or as a fence-connector combination for new fence installations. As a benefit, such methods and system allow fencing structures used to contain large animals (e.g., rail fencing), such as horses, to have a wire or other fabric attached to contain, for example, smaller animals and children.

RELATED APPLICATION

This application is a non-provisional application which claims priority to application 60/440,502, entitled “METHODS AND SYSTEMS FOR NON-INVASIVE ATTACHMENT OF MESH FENCING TO AN EXISTING FENCING SYSTEM”, filed Jan. 16, 2003, and is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

Plastic fencing materials, typically poly vinyl chloride (“PVC”), provides property owners with fencing options not previously available with metal or wood. These near zero maintenance fencing products provide the functional and aesthetic properties of wood but without the need for the maintenance required by wood or metal materials.

Plastic fencing is commonly 2, 3, 4, and 5-rail, and segmented solid and semi-solid panels. The rail fencing has grown in popularity, as it possesses beneficial aesthetic properties as well as the ability to contain large animals, such as, horses and livestock.

Many property owners want the properties of rail fencing but also want to provide a barrier to small animals and children. Property owners who install mesh fencing, for example, wire mesh or chain link, are faced with no real option of incorporating a mesh into a plastic fencing system. Manufacturers of prior art plastic fencing emphasize that penetration of the surface of their fencing products, by drilling, screwing, or nailing, or applying a surface load, such as by gluing, may cause points of stress which may result in cracking and ultimately failure of the fencing member. Manufacturers commonly void their warranty, if the fencing member is altered in such a manner.

As a limitation of the prior art of fencing systems, property owners are left with two options for incorporating a mesh fence into a plastic fencing system. First, property owners may build a substantially independent fence. This fence-within-a-fence provides the benefit of two fencing types, as it is two complete fences, but there is no ability to leverage the work and expense incurred with one fence by the second. The property owner must pay the cost to install two fences, maintain two fences, maintain the property grounds obstructed by two fences, develop a complex gate system, and lose usable property to the space between the two fences.

Second, property owners may attach mesh fencing directly to some members of the plastic fence with wire-ties, plastic “zip” ties, rope or twine. Not only does such a method defeat much of the aesthetic utility provided by plastic fencing, but such ties may become slack, discolor, dry-rot, photo-decay, and/or mar the fence. Additionally, plastic fencing is not designed to accommodate a lateral load, which is induced with mesh fencing.

SUMMARY OF THE INVENTION

In one aspect, methods and systems are provided to attach a mesh (e.g., wire, plastic, or other fabric) to an existing fencing frame. The mesh is attached to substantially hang on the existing fence post (“post”) members and provide minimal lateral force on the posts. A mesh is attached between posts to form a section. As a benefit, a method of mesh attachment is available wherein the tension of mesh between panels does not substantially accumulate from one section to another, resulting in a net-zero lateral force for every post, with the exception of end, corner, and gate posts where the lateral force is substantially equal to the lateral tension force of one section of mesh.

In another aspect, lateral tension on the posts may be reduced by non-evasive (e.g., without penetrating, fusing with, or bonding to the surface of the post) cross bracing and connectors to provide a transfer of lateral force to near the ground of a post and may accommodate the application of a tensioned mesh. The brackets to support the cross bracing may frictionally engage the post in tension or compression. In one preferred embodiment the cross-brace bracket engages the horizontal fence member (e.g., rails) to support the cross-brace in tension or compression. As an option, evasive attachment of cross bracing is also provided.

In another aspect, a system of fencing is provided wherein a connector is integrated into the post to facilitate the attachment of a mesh. For example, a PVC extrusion may output a substantially square post, for the acceptance of rails, with an integrated tensioner to facilitate the application of a mesh. The tensioner may be round, and, as a matter of design choice, integrate a metal insert. The tensioner may be held away from the post with one or more connecting ribs (“braces”) to facilitate wrapping a wire between the post and the tensioner. Optionally, the tensioner may accommodate punches, screws, nails, clamps, glues, welds, and drilling to allow the integrity of the post to be preserved.

In another aspect, the internal structure of the post may be enhanced with internal spars (“bridging”) to increase the strength and provide support to the braces and/or tensioner without impeding the placement of horizontal elements (e.g., rails). As an additional design choice, the bridge geometry may facilitate strengthening the posts, braces, and/or tensioner when by engaging concrete poured into the post.

As those skilled in the art would appreciate, the systems and methods herein may apply to plastic, metal, wood, stone, or other type of fencing materials and rail, slat, lattice, or other type of fencing construction systems and therefore may benefit from the disclosed mesh attachment systems and methods disclosed herein. Also apparent to those skilled in the art is application of subcomponents to facilitate installation of components wherein the plastic fence has been installed, as well as, the manufacture of components, disclosed herein, integrated into posts which may provide additional benefits in new fence installations.

The invention is next described further in connection with preferred embodiments, and it will become apparent that various additions, subtractions, and modifications can be made by those skilled in the art without departing from the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a prior art plastic fencing system;

FIG. 2 shows an exemplary fence section with attached mesh;

FIG. 3 shows an exemplary gate section with attached mesh and extended connectors;

FIGS. 4A-B show an exemplary integrated tensioner and post;

FIG. 5 shows a top view of an exemplary integrated tensioner and post with internal bridging;

FIG. 6 shows a top view of an exemplary corner post with integrated tensioner and internal bridging;

FIGS. 7A-C show an exemplary segmented connector useful in installations in which the rails remain in place;

FIGS. 8A-B shows an exemplary connector useful to limit motion by engaging a horizontal fencing member; and

FIG. 9 shows a cross-section of an exemplary post with two exemplary internal mesh attachment configurations.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows prior art plastic fencing system 10 commonly utilizing PVC materials. Posts 20 provide support to rails 18 and are partially embedded into the ground (shown in outline). Gate 12 utilizes latch 14 and hinges 16.

FIG. 2 shows exemplary fencing system 100 containing mesh 122 forming a fence section. The section contains posts 106A-B and rails 110A-C (visible through a portion of mesh 122, removed for clarity). Each post 106A-B contains openings to contain an end of each of rails 110A-C. Rails 110A-C may be attached to posts 106A-B by tabs or locking pins, or as otherwise currently known in the art. Fencing mesh 122, provides additional fencing properties, such as, confinement of household pets, children, or visual screening and may be selected from chain link, wire mesh, plastic fabric, or other material suitable to provide the additional fencing properties desired.

Connectors 102, 104, 108, 112, 116, 118 provide a connection to the posts 106A-B and mesh 122 directly or with the optional implementation of tensioner 120 (post 106A also contains a tensioner but it would not be visible from the visual prospective provided and installation illustrated by FIG. 2). As an option, the tensioners may be placed on the face of posts 106A-B, in addition to the rail (“side”) installation illustrated by FIG. 2. Connectors 102, 104, 108, 112, 116, 118 may be manufactured from metal, plastic, and/or other material to narrowly accommodate the post once installed. Connectors 102, 104, 108, 112, 116, 118 may be segmented and combined in place to facilitate placement on posts 106A-B without removal of rails 110A-C. Connectors 102, 104, 108, 112, 116, 118 may be fabricated with fewer pieces or as a single piece, to facilitate rail installation before, during, or after the installation of connectors 102, 104, 108, 112, 116, 118, as a matter of design choice.

Connectors 102, 104, 108, 112, 116, 118 provide an attachment point for mesh 122 or, optionally, a second connector to accommodate fence tensioner 120. For example, a second connector may be a “C” shaped open tube for insertion over tensioner 120 and attachment of fence mesh 122. Other means to attach mesh 122 to tensioner 120 include mechanical fasteners, such as ties and/or clips. Tensioner 120 may then provide a connection point for mesh 122 as a continuous fencing member, when face mounted, or in segments, when side mounted, as a matter of design choice. For example, tensioner 120 may provide greater installation flexibility as one continuous piece, however, tensioner 120 may be attachment hardware, such as eye-hooks, tabs, t-hooks, brackets, or other attachment points to facilitate attachment of mesh 122 in addition to the continuous rod illustrated by FIG. 2.

Upper connectors 108, 112 are attached to post 106A and 106B, respectively, to resist downward motion by engaging top rail 110C. Lower connectors 104, 116 are attached on posts 106A and 106B, respectively, to resist upward motion by engaging lower rail 120A. Ground level connectors 102, 118 are optionally provided and provide additional mounting points for tensioner 120. The geometry of the connectors, such as connector 104, 108, 112, 116 may allow the face portion of connectors 104, 108, 112, 116 to be substantially in alignment with the rails and, as a benefit, provide a visual alignment with and/or illusion of continuation of the rails. One example of such a connector is provided by FIG. 8. Optionally, connectors 102, 104, 108, 112, 118 may resist upward and downward force by engaging the upper and/or lower surfaces of one or more of rails 110A-C and/or frictionally engaging posts 106A-B. As a matter of design choice, connectors 102, 104, 108, 112, 116, 118 may be engage posts 106A-B with glue or mechanical fasteners.

As those skilled in the art will appreciate, the selection of a highly rigid mesh, such as mesh 122, requires less tension to prevent deforming and fewer connections, such as connectors, 102, 104, 108, 112, 116, 118 to maintain tension. The material and size selected, as a matter of design choice, of tensioner 120 may also reduce or increase the quantity and strength of connectors 102, 104, 108, 112, 116, 118.

As those skilled in the art will appreciate, connectors 102, 104, 108, 112, 116, 118 may be modified as a matter of design choice, to accommodate a cross brace and/or lateral brace to support a high-tension mesh in addition to, or as a complement to, a mesh attachment points, such as provided by tensioner 120.

FIG. 3 shows exemplary gate section 200 with mesh 21 f 8 attached. Gate 200 comprises vertical members 206A-B and horizontal members 210A-C (visible through a region of mesh 218 removed for clarity). Connectors 204, 208, 212, 214 provide a connection to vertical members 206A-B and mesh 218 directly or with optional tensioners 202, 216. Vertical members 206A-B may provide ground clearance as needed to provide free motion of the gate over uneven ground, vegetation, or other obstacles. Tensioners 202, 216 may optionally be extended close to the ground to provide mesh 218 with tension close to the ground. As a benefit, mesh 218 resists deformation when opening and closing the gate where the mesh may drag on the ground or be deformed by, for example, household pets.

Connectors 208, 212 may engage top horizontal member 210C to resist downward motion and similarly connectors 204, 214 may engage bottom horizontal member 201A to resist upward motion. As a matter of design choice connectors 204, 208, 212, 214 may engage vertical members 206A-B and/or horizontal member 210A-C by friction, glue, or mechanical fasteners.

As those skilled in the art will appreciate, such methods of non-invasive attachment of connectors to a plastic fence can accommodate invasive connection methods and/or joint fabrication of components, as a matter of design and implementation choice.

FIGS. 4A-B show exemplary integrated tensioner 302 and post 300. Integrated tensioner 302 illustrates one integrated connector. Connectors, integrated into a post or installed onto a post, provide attachment points for the mesh fabric, or additional hardware to attach the mesh fabric, and may have other geometries as a matter of design choice. FIG. 4A primarily shows a face prospective of post 300 and FIG. 4B shows a side, or “rail,” prospective of post 300. Post 300 has a plurality of openings 308 to accommodate horizontal members, such as rails. Post 300 has a plurality of braces 304A-F to attach tensioner 302. Tensioner 302 provides a support for attachment of a mesh fencing material by providing a connection point. Braces 304A-F may be combined into one brace, which in turn attaches to tensioner 302. Tensioner 302 may accommodate secondary connectors, for example, tensioner 302 may be a round rod and accommodate one or more “C” connectors for attachment of a mesh to the “C” connector. Additionally a clamp or other attachment device may be provided to further support the mechanical link between tensioner 302 and the mesh. For example, the gap defined by post 300, tensioner 302, and each of the plurality of braces 304 could accommodate wire ties attaching a mesh. As an implementation option post 300, tensioner 302, and braces 304 may be formed by extrusion or other fabrication process and, optionally, holds drilled, punched, or otherwise created to form voids to accommodate the attachment of a mesh.

As a matter of design choice, tensioner 302 may be attached to the face of post 300, as shown in FIGS. 4A-B. As a benefit of such an orientation, the attachment of a mesh may be performed faster as a mesh would not be required to terminate at each tensioner 302 and therefore not have to be cut at each tensioner 302. As another design choice, tensioner 302 may be placed on the “rail” side of post 300. As a benefit of such an orientation, the attachment of a mesh is placed close to the rails and may produce a more desirable appearance.

As another benefit, tensioner 302 may provide a surface suitable for drilling, gluing, welding, nailing, or otherwise penetrating the surface of tensioner 302 without unduly stressing post 300.

In another aspect, tensioner 302 may extend from substantially near the top of post 300 to close to the ground after installation. As a matter of design choice, tensioner 302 may extend below the ground level, when installed, and may provide additional stability. As a further option, tensioner 302 may incorporate additional materials, such as a wire rod, to provide additional strength and/or stiffness.

FIG. 5 shows a top view of a “run” post system 500 with post 502 to accommodate horizontal members, such as rails 504A-B in a substantially linear installation. Post 502 has braces 508A-B attached to tensioners 506A-B, respectively. Tensioner 506A-B may then accommodate the attachment of a mesh or other mesh-attachment hardware. Internal bridging 510 provides additional strength. Bridging 510 may be solid, uniform, segmented, and/or perforated, as a matter of design choice, manufacturing limitations, weight, strength, and/or other attribute. As a further design choice, bridge 510 may be designed to engage concrete, aggregate, or other post filler material placed inside of post 502.

As those skilled in the art will appreciate, FIG. 5 may omit one brace-connector pair, for example, brace 508B and connector 506B, for application in an end post or vertical gate member.

FIG. 6 shows a top view of corner post system 600 with post 602 operable to accommodate horizontal members, such as rails 602A-B in a substantially right-angle installation. Post 602 has (visible) braces 608A-B attached to tensioner 606A-B, respectively. Tensioner 606A-B may accommodate the attachment of a mesh or other mesh attaching hardware. Internal bridging 610 provides additional strength. Bridging 610 may be solid, uniform, segmented, and/or perforated as a matter of design choice. As an additional design choice, bridge 610 may have openings to accommodate rails 604A-B. As an additional design choice, bridge 610 may be designed to engage concrete, aggregate, or other post filler material placed inside of post 602. As a further design option, a filling material, such as concrete, may sufficiently bond to the interior surface of post 602 to provide a partial or total replacement of bridge 610. Bridging 510 may, therefore, be solid, uniform, segmented, and/or perforated, or omitted, as a matter of design choice.

FIGS. 7A-C show exemplary connector 704 segmented to facilitate installation onto post 700 without requiring the removal of installed rails (not shown for clarity). Connectors 704A-B are shown in FIG. 7A installed with tensioner 706 to accommodate the installation of a mesh. FIG. 7B shows connector 704 with hinge 710 to accommodate opening of connector 710. Here the connector contains a plurality of rings 708 to narrowly accommodate tensioner 706 when installed through the path 711 (shown as a broken line). FIG. 7C shows connector 704 in a closed position with tensions 706 passing through each of the plurality of rings 708. Hinge 710 is substantially flat. As a design option, two or more joinable subcomponents connected by a tab, pin, latch, glue, weld, or other joining means may form connector 704.

Tensioner 706 may further resist motion inside the plurality of rings 708 by texturing the surface of the inside of at least one of the plurality of rings 708 or tensioner 706, or by the application of friction inducing material, adhesive, or mechanical fastener.

As those skilled in the art will appreciate, the plurality of rings 708 may be attached directly to post 700, for example, during manufacture of a post containing an integrated combination of post 700 and mesh attachment hardware, such as, a hook, plurality of rings 708, or a single ring. As a further design option, connector 704 can be a solid piece as a benefit to those installing a fencing system where the rails are not yet in place or are removed. Furthermore, connector 704 may accommodate the attachment of a tensioner, such as tensioner 706 shown and/or a cross-brace.

FIGS. 8A-B shows exemplary connector 800. Connector 800 contains notch 804 to engage a horizontal member to resist downward motion, when installed in the orientation shown by FIGS. 8A-B, or to resist upward motion when installed in the orientation in which notch 804 faces upwards. Ring 802 is operable to narrowly accommodates a tensioner and is attached to connector 800 by brace 806.

As a matter of design choice, joinable connector 808 may optionally be connected to connector 800. As a benefit of implementation of locking connector 808, one connector may resist motion both upwards and downwards. Optionally, locking connector 808 may contain notch 810 to accommodate a horizontal member. As a further option, locking member 808 may contain a second ring to accommodate the tensioner.

As a benefit to the geometry provided by connector 800, the most visible (face) side of connector 800 appears in alignment with an installed rail after assembly of a post-connector-rail segment of a fence. As those skilled in the art will appreciate, connector 800 may be made in segments to accommodate installation with existing rails and connector 800 may accommodate a cross-brace.

FIG. 9 shows a top view of exemplary post 900 with slots to accept spline inserts 903 and 912. The combination of both spline inserts 903, 912 on one post is a design option, however, it is illustrative of two positioning options, namely face, as illustrated by spline insert 903, and side, as illustrated by spline insert 912. As a matter of design choice, spline insert 903, 912 may be positioned at the corner of post 900. Spline insert 912 is operable to accommodate the installation of a mesh close to the rails and spline insert 903 is operable to accommodate the installation of the mesh further away from the rails. FIG. 9 illustrates post 900 as a “run” post (e.g., the fence installation is substantially linear when viewed from above) with rails 902A-B, as those skilled in the art will appreciate, post 900 may be an end post, gate post, corner post, or other configuration. Spline insert 903 shows optional anchor 904 attached to exposed ring 906. Ring 906 is attached to wire 910 with tie 908. Similarly, spline insert 912 utilizes optional anchor 914 to hold wire 916.

As those skilled in the art will appreciate, the geometry of spline inserts 903, 912 is designed to resist the motion of the attached mesh, here shown as a wire, and maintain the strength of post 900. Other geometries and configurations may be utilized for the spline inserts as a matter of design choice, for example; 1) the irregular geometry shown by spline inserts 903 and 912 may accept another insert such as a rod—similar to anchor 914—in which the mesh material is attached; 2) a regular geometry to accept, for example, a mesh rapped around a rod; 3) the spline inserts may additionally provide a spring to tension the mesh material; or 4) the spline inserts may be fabricated as a continuous member of post 900 with wire 916, 910 embedded within. In addition to the spline inserts having the mesh material embedded directly into the spline, the splines may attach, or embed, other connection hardware, which in turn attaches to the mesh material. Internal bridging, as described in FIGS. 5, 6 may also be implemented, as a matter of design choice, to provide additional strength.

Furthermore, the examples provided herein illustrate preferred methods and systems. Other options such as; 1) connectors engaging a post without a tensioner, in which a mesh is attached directly to the connector (e.g., a connector with an eye-hook or “T” tab), 2) connectors modified with rings, pins, sockets, and/or other hardware to support a cross-brace as a complement to, or in stead of, hardware supporting mesh attachment, 3) other equivalents to those herein, may also be implemented without departing from the disclosures provided herein.

The invention thus attains the object set forth above, among those apparent form preceding description. Since certain changes may be made in the above systems and methods without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. 

1. A method of multiple purpose fence construction, comprising the steps of: non-invasive placement of a connector on a fence post with a first fencing material; and attaching a second fencing material to the connector.
 2. A method of claim 1, wherein the placement step further comprises, the steps of: assembling the connector from a plurality of connector segments.
 3. A method of claim 1, wherein the placement step further comprises, the step of placing the connector on a fence post to engage a fence member attached to the fence post and thereby limiting motion of the connector along the fence post.
 4. A method of claim 1, wherein the placement step further comprises, placing the connector narrowly onto the post to resist motion along the post by friction with the post.
 5. A method of claim 1, wherein the placement step further comprises, placing the connector onto the post to resist motion along the post by engaging at least one of, adhesive, screw, pin, bolt, nail, weld, tab, rib, eccentric, latch, and socket.
 6. A method of claim 1, wherein the step of attaching the second fencing material to the connector further comprises, attaching a tensioner to the connector, the connector being operable to accommodate attachment of the second fencing material.
 7. A method of claim 1, wherein the placement step further comprises the placement of a connector on a fence post, wherein the fence post is a gate post.
 8. A fence system comprising: a fence post operable to support a first fencing material; and a connector operable to narrowly fit onto the fence post and operable to accept the attachment of a second fencing material.
 9. A connector of claim 8 further comprising: a plurality of joinable segments operable to form the connector.
 10. A connector of claim 8 further comprising: an openable connector operable to form the connector.
 11. A connector of claim 8 further comprising: a connector operable to accept a tensioner; and a tensioner operable to support the attachment of the second fencing material.
 12. A connector of claim 8 further comprising, a second connector operable to support attachment of the second fencing material.
 13. A fence post of claim 8 further comprising a gate post.
 14. A fence post comprising: a fence post operable to support a first fencing material; and an integrated connector operable to support a second fencing material.
 15. A fence post of claim 14 further comprising: an interior bridge connected to the interior wall of the fence post operable to provide additional strength to the fence post.
 16. A fence post comprising: a fence post operable to support a first fencing material; a receptacle to accept a spline, and the spline being operable to support the attachment of a second fencing material. 